Raypak MVB 5042004 User Manual
INSTALLATION & OPERATING
L
W
INSTRUCTIONS
Models 504–2004
Types H, WH, P & WHP
WARNING: Improper installation, adjustment, alteration, service or maintenance can
cause property damage, personal injury, exposure to hazardous materials* or loss of
life. Review the information in this manual carefully. *This unit contains materials that
have been identified as carcinogenic, or possibly carcinogenic, to humans.
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and
liquids or other combustible materials in the vicinity of this or any other appliance. To
do so may result in an explosion or fire.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.
CATALOG NO. 3400.54E Effective: 03-25-10 Replaces: 03-19-09 P/N 241317 Rev. 6
Rev. 5 reflects the following:
Changes to: Air Filter instructions on page 11, minor text changes on pages 13 and 14, Figs. 10 and 11 on page 15,. Fig 12
and Table G on page 16, Fig 13 on page 17, minor text changes on page 20, Fig. 21 on page 22, Figs. 22-28 on pages 2530, Table N on page 29, Fig. 35 on page 32, Mode 8 description on page 33, minor text changes on pages 42, 43 and 46,
Troubleshooting chart on page 48.
Additions: Fig. 2 on page 6, Low-lead requirement on page 5, Fig. 8 on page 11, note on page 12, Caution on page 20, Fig.
22 on page 22, Fig. 36 on page 33, air filter instructions on pages 50 and 51.
2
CONTENTS
WARNINGS 4
BEFORE INSTALLATION 5
Product Receipt 5
Model Identification 5
Ratings and Certifications 5
Installations at Elevation 5
Component Locations 6
General Information 6
GENERAL SAFETY 7
Time/Temperature Relationships in
Scalds 7
INSTALLATION 8
Installation Codes 8
Equipment Base 8
Clearances 8
Combustion and Ventilation Air 9
Conventional Combustion Air Supply 11
Water Piping 12
Hydronic Heating 14
Gas Supply 19
Electrical Power Connections 20
Field Wiring Connection 22
Venting 22
Venting Installation Tips 24
Venting Configurations 24
Engineered Vent Systems 27
Outdoor Installation 29
Controls 30
Heater Sequence of Operation 37
WIRING DIAGRAMS 40
START-UP 42
Pre Start-up 42
Start-Up 43
OPERATION 46
Lighting Instructions 46
To Turn Off Gas To Appliance 47
UDB Fault History 47
TROUBLESHOOTING 48
MAINTENANCE 49
Suggested Minimum
Maintenance Schedule 49
Preventative Maintenance Schedule 49
Filter Maintenance 50
Filter Replacement 51
APPENDIX 51
Inside Air Contamination 51
IMPORTANT INSTRUCTIONS FOR
THE COMMONWEALTH OF
MASSACHUSETTS 52
WARRANTY 53
START-UP CHECKLIST 55
3
WARNINGS
Pay Attention to These Terms
ndicates the presence of immediate hazards which will cause severe
DANGER:
I
personal injury, death or substantial property damage if ignored.
WARNING:
CAUTION:
NOTE:
DANGER: Make sure the gas on which the heater
will operate is the same type as that specified on the
heater rating plate.
WARNING: Should overheating occur or the gas
supply valve fail to shut, do not turn off or disconnect
the electrical supply to the heater. Instead, shut off
the gas supply at a location external to the heater.
WARNING: Do not use this heater if any part has
been under water. Immediately call a qualified
service technician to inspect the heater and to
replace any part of the control system and any gas
control which has been under water.
WARNING: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:
• Always keep the area around the heater free of
combustible materials, gasoline, and other
flammable liquids and vapors.
• Heater should never be covered or have any
blockage to the flow of fresh air to the heater.
WARNING: Risk of electrical shock. More than one
disconnect switch may be required to de-energize
the equipment before servicing.
Indicates the presence of hazards or unsafe practices which could cause
severe personal injury, death or substantial property damage if ignored.
Indicates the presence of hazards or unsafe practices which could cause
minor personal injury or product or property damage if ignored.
Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.
CAUTION: Operation of this heater in low
temperature systems requires special piping.
Harmful internal condensation will occur if the inlet
water temperature does not exceed 120°F. Warranty
claims will be denied when condensation occurs.
CAUTION: If this heater is to be installed above
radiation level, it must be provided with a low water
cut-off device at the time of heater installation.
CAUTION: This heater requires forced water
circulation when the burner is operating. See
minimum and maximum flow rates. Severe damage
will occur if the heater is operated without proper
water flow circulation.
CAUTION: If this heater is to be installed in a
negative or positive pressure equipment room, there
are special installation requirements. Consult factory
for details.
NOTE: Minimum 18 AWG, 105°C, stranded wire
must be used for all low voltage (less than 30 volts)
external connections to the unit. Solid conductors
should not be used because they can cause
excessive tension on contact points. Install conduit
as appropriate. All high voltage wires must be the
same size (105°C, stranded wire) as the ones on the
unit or larger.
WARNING - CALIFORNIA PROPOSITION
65: This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.
4
BEFORE INSTALLATION
Raypak strongly recommends that this manual be reviewed thoroughly before installing your MVB heater.
Please review the General Safety information before
installing the heater. Factory warranty does not apply
to heaters that have been improperly installed or operated. (Refer to the warranty at the back of this
manual.) Installation and service must be performed
by a qualified installer, service agency or gas supplier.
If, after reviewing this manual, you still have questions
which this manual does not answer, please contact
your local Raypak representative or visit our website at
www.raypak.com.
he upper rear jacket panel of the heater. The model
t
number will have the form H7-2004 or similar depending on the heater size and configuration. The letter(s)
in the first group of characters identifies the application
H = Hydronic Heating, P = Pool Heating, WH =
(
Domestic Hot Water (DHW), WHP = Water Heater for
ool Heating). The number which follows identifies the
P
firing mode (7 = electronic modulation, 1 = On/Off).
The second group of characters identifies the size of
the heater (three or four numbers representing the
approximate MBTUH input), and, where applicable, a
letter, indicating the manufacturing series.
Ratings and Certifications
Thank you for purchasing a Raypak product. We hope
you will be satisfied with the high quality and durability
of our equipment.
Product Receipt
On receipt of your heater it is suggested that you visually check for external damage to the shipping crate. If
the crate is damaged, make a note to that effect on the
Bill of Lading when signing for the shipment. Next,
remove the heater from the shipping packaging.
Report any damage to the carrier immediately.
On occasion, items are shipped loose. Be sure that
you receive the correct number of packages as indicated on the Bill of Lading.
Claims for shortages and damages must be filed with
the carrier by consignee. Permission to return goods
must be received from the factory prior to shipping.
Goods returned to the factory without an authorized
Returned Goods Receipt number will not be accepted.
All returned goods are subject to a restocking charge.
When ordering parts, you must specify the model and
serial number of the heater. When ordering under warranty conditions, you must also specify the date of
installation.
Purchased parts are subject to replacement only
under the manufacturer’s warranty. Debits for defective replacement parts will not be accepted. Parts will
be replaced in kind only per Raypak’s standard warranties.
Model Identification
The model identification number and heater serial
number are found on the heater rating plate located on
Standards:
• ANSI Z21.56 · CSA 4.7 - latest edition, Gas-Fired
Pool Heaters
• ANSI Z21.13 · CSA 4.9 - latest edition, Gas-Fired
Hot Water Boilers
• CAN 3.1 - latest edition, Industrial and
Commercial Gas-Fired Package Boilers
• ANSI Z21.10.3 · CSA 4.3 - latest edition, Gas Water Heaters
• SCAQMD Rule 1146.2
• Low-lead content (<.25%) CSA-verified
All Raypak heaters are National Board Approved, and
design-certified and tested by the Canadian Standards
Association (CSA) for the U.S. and Canada. Each
heater is constructed in accordance with Section IV of
the American Society of Mechanical Engineers
(ASME) Heater Pressure Vessel Code and bears the
ASME stamp. This heater also complies with the latest
edition of the ASHRAE 90.1 Standard.
WARNING: Altering any Raypak pressure vessel
by installing replacement heat exchangers, tube
bundle headers, or any ASME parts not
manufactured and/or approved by Raypak will
instantly void the ASME and CSA ratings of the
vessel and any Raypak warranty on the vessel.
Altering the ASME or CSA ratings of the vessel also
violates national, state, and local approval codes.
Installations at Elevation
Rated inputs are suitable for up to 4,500 ft elevation
without de-rating. Consult your local representative or
the factory for installations at altitudes over 4,500 ft
above sea level. No hardware changes are required to
the heaters for installations up to 10,000 ft (adjustments may be required).
5
HIGH VOLTAGE
ELECTRICAL CONNECTIONS
Component Locations
Fig. 3: Component Locations – Rear
Panels omitted for clarity
Fig. 1: Component Locations – Side
Top panel, blower and gas train omitted for clarity
Fig. 4: Component Locations – Top
General Information
Model
No.
504 500 350 2 1 1 8 6
754 750 525 2 1 1 10 6
1104 1100 770 2-1/2 1-1/4 1 10 6
1504 1500 1050 2-1/2 1-1/4 1 12 8
MBTUH
Input*
Max.* Min.* N P Flue Intake
Water
Conn.
(NPT)
Gas
Conn.
(NPT)
Vent
Size
(in.)
Panels omitted for clarity
Fig. 2: Component Locations – Front
2004 1999 1400 2-1/2 2 1 14 8
*H7 units only.
Table A: Basic Data
6
GENERAL SAFETY
Water temperature over 125°F can
cause instant severe burns or death
from scalds.
Children, disabled, and elderly are
at highest risk of being scalded.
See instruction manual before setting temperature at water heater.
Feel water before bathing or showering.
Temperature limiting valves are
available, see manual.
Water
Temp.
Time to Produce Serious
Burn
120°F More than 5 minutes
125°F 1-1/2 to 2 minutes
130°F About 30 seconds
135°F About 10 seconds
140°F Less than 5 seconds
145°F Less than 3 seconds
150°F About 1-1/2 seconds
155°F About 1 second
Table courtesy of The Shriners Burn Institute
To meet commercial hot water use needs, the high
limit safety control on this water heater will shut off the
main gas valve before the outlet temperature reaches
210°F. However, water temperatures over 125°F can
cause instant severe burns or death from scalds.
When supplying general purpose hot water, the recommended initial setting for the temperature control is
125°F.
This section applies to Hot Water Supply Boilers and
Hot Water Heaters ONLY. For sanitary rinse applications where outlet temperatures of 180°F to 195°F are
required, a boiler is recommended since the 210°F
limit on water heaters will NOT allow the heater to
maintain these desired sanitary rinse temperatures.
Safety and energy conservation are factors to be considered when setting the water temperature on the
thermostat. The most energy-efficient operation will
result when the temperature setting is the lowest that
satisfies the needs of the application.
Water temperature over 125°F can cause instant
severe burns or death from scalds. Children, disabled
and elderly are at highest risk of being scalded.
• Feel water before bathing or showering.
• Temperature limiting valves are available.
NOTE: When this water heater is supplying general
purpose hot water for use by individuals, a
thermostatically controlled mixing valve for reducing
point of use water temperature is recommended to
reduce the risk of scald injury. Contact a licensed
plumber or the local plumbing authority for further
information.
Maximum water temperatures occur just after the
heater’s burner has shut off. To determine the water
temperature being delivered, turn on a hot water
faucet and place a thermometer in the hot water
stream and read the thermometer.
Time/Temperature
Relationships in Scalds
The following chart details the relationship of water
temperature and time with regard to scald injury and
may be used as a guide in determining the safest
water temperature for your applications.
Table B: Time to Produce Serious Burn
7
Heater
Side
Minimum Clearance
from Combustible
Surfaces
Minimum
Service
Clearance
Floor* 0” 0”
Rear 12” 24”
Right
Side
1” 1”
Left Side 1” 1”
Top 0” 10”
Front Open 24”
Vent 1” 1”
The temperature of the water in the heater can be regulated by using the Raypak Modulating Temperature
Control. To comply with safety regulations, the control
is set at 120°F when shipped from the factory (Mode 3
default setting for Tank Target).
To adjust the water temperature, follow the instruction
for the operation of the control starting on page 30 of
this manual. The control is shown below for identification purposes only. (See Fig. 5.)
Equipment Base
The heater should be mounted on a level, structurally
ound surface. The heater is approved for installation
s
on a combustible surface but must NEVER be
nstalled on carpeting. Gas-fueled equipment installed
i
in enclosed parking garages must be located at least
18 in. above the floor.
CAUTION: This heater should be located in an
area where water leakage will not result in damage
to the area adjacent to the appliances or to the
structure. When such locations cannot be avoided, it
is recommended that a suitable catch pan,
adequately drained, be installed under the
appliance. The pan must not restrict air flow.
In addition, the heater shall be installed such that the
gas ignition system components are protected from
water (dripping, spraying, rain, etc.) during appliance
operation or service (circulator replacement, control
replacement, etc.).
Fig. 5: Modulating Temperature Control
CAUTION: Hotter water increases the risk of
scalding! There is a hot water scald potential if the
thermostat is set too high.
INSTALLATION
INSTALLATION
Installation Codes
Installations must follow these codes:
• Local, state, provincial, and national codes, laws,
regulations and ordinances
• National Fuel Gas Code, ANSI Z223.1/NFPA 54 –
latest edition (NFGC)
• National Electrical Code, ANSI/NFPA 70 - latest
edition (NEC)
• Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1,
(CSD-1) when required
• For Canada only: CAN/CSA B149 Natural Gas
and Propane Installation Code and CSA C22.1
C.E.C. Part 1 (C22.1)
If the heater needs to be secured to the ground, use
the brackets that were used to bolt the heater to the
shipping pallet.
Clearances
Indoor Installations
*DO NOT install on carpeting.
Table C: Clearances – Indoor Installations
When installed according to the listed minimum clearances from combustible construction, these heaters
can still be serviced without removing permanent
structural construction around the heater. However, for
ease of servicing, a clearance of at least 24 in. in front,
at least 24 in. on the rear and 10 in. above the top of
the heater is required. This will allow the heater to be
8
odes and the requirments of the gas supplier. Three
c
sides must be open in the area under the overhang.
Roof water drainage must be diverted away from
heaters installed under overhangs.
The combustion air intake terminal MUST be used for
utdoor installations. The elbow is shipped loose to be
o
installed on the rear of the heater at the job site.
Heater
Side
Rear 12” 24”
Front Open 24”
Right Side 1” 1”
Left Side 1” 1”
Top Unobstructed 10”
Vent
Termination
Table D: Clearances – Outdoor Installations
Min. Clearance
from Combustible
Surfaces
12” 12”
Minimum
Service
Clearance
Combustion and Ventilation Air
NOTE: Use of this heater in construction areas
where fine particulate matter, such as concrete or
dry-wall dust, is present may result in damage to the
heater that is not covered by the warranty. If
operated in a construction environment, a clean
source of combustion air must be provided directly to
the heater.
Venting not shown for clarity. Heater must be vented per instruc-
tions in this manual
Fig. 6: Minimum Clearances from Combustible
Surfaces – Indoor and Outdoor Installations
serviced in its installed location without movement or
removal of the heater.
Service clearances less than the minimum may
require removal of the heater to service either the heat
exchanger or the burner components. In either case,
the heater must be installed in a manner that will
enable the heater to be serviced without removing any
structure around the heater.
Outdoor Installations
These heaters are design-certified for outdoor installation. Heaters must not be installed under an overhang
unless they are in accordance with local installation
Indoor Units
This heater must be supplied with sufficient quantities
of non-contaminated air to support proper combustion
and equipment ventilation. Combustion air can be supplied via conventional means where combustion air is
drawn from the area immediately surrounding the
heater, or via direct vent, where combustion air is
drawn directly from outside. All installations must comply with the requirements of the NFGC (U.S.) and
B149 (Canada), and all local codes.
CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the heater and void the warranty. (See
the Appendix.)
NOTE: It is recommended that the intake vent be
insulated to minimize sweating.
9
U.S. Installations
1
Canadian Insta llations
2
A
Clearance above grade, veranda, porch,
deck, or balcony
1 ft (30 cm) 1 ft (30 cm)
B
Clearance to window or door that may be
opened
4 ft (1.2m) below or to side
of opening; 1 foot (30 cm)
above opening
3 ft (91 cm)
C Clearance to permanently closed window **
D
Vertical clearance to ventilated soffit located
above the terminal within a horizontal distance of 2 ft (61cm) from the centerline of the
terminal
5 ft (1.5m) *
E Clearance to unventilated soffit **
F Clearance to outside corner **
G Clearance to inside corner 6 ft (1.83m) *
H
Clearance to each side of center line ex-
tended above meter/regulator assembly
*
3 ft (91 cm) within a height
15 ft above the me-
ter/regulator assembly
I Clearance to service regulator vent outlet * 6 ft (1.83m)
J
Clearance to non-mechanical air supply inlet
to building or the combustion air inlet to any
other appliance
4 ft (1.2m) below or to side
of opening; 1 ft (30 cm)
above opening
3 ft (91 cm)
K Clearance to mechanical air supply inlet
3 ft (91 cm) above if within
10 ft (3m) horizontally
6 ft (1.83m)
L
Clearance above paved sidewalk or paved
driveway located on public property
7 ft (2.13m)
7 ft (2.13m) t
M
Clearance under veranda, porch, deck or
balcony
* 12 in. (30 cm) TT
1
In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code
2
In accordance with the current CAN/CGA-B149 Installation Codes
t Vent terminal shall not terminate dir ectly above sidewalk or paved driveway located between 2 single family dwellings that s erves
both dwellings
TT Permitted only if veranda, porc h, deck, or balcony is fully open on a minimum of two sides beneath the floor and top of terminal and
underside of veranda, porch, deck or balcony is greater than 1 ft (30c m)
* Clearances in accordance with local installation codes and the requirements of the gas supplier
Fig. 7: Minimum Clearances from Vent/Air Inlet Terminations – Indoor and Outdoor Installations
Table E: Vent/Air Inlet Termination Clearances
10
Air Filter
An air filter is supplied standard with the heater. This
filter is shipped loose for field installation. Refer to the
Air Filter Kit Installation Instructions (Part No. 241338)
for details.
r sealed single-wall galvanized ducting. The duct will
o
attach directly to the air collar located on the rear of the
heater, using three or four sheet metal screws (not
supplied) equally positioned around the circumference
f the duct. The screen assembly should be removed
o
before attaching any air duct to the heater. The screws
nd duct connection point must be sealed with RTV
a
(not supplied). TruSeal is generally used when damaging contaminants are present in the mechanical
room.
All ducting must be self-supported.
CAUTION: Use TruSeal combustion air if
damaging airborne contaminants are or may be
present in the heater area. See the Appendix of this
manual regarding air contamination.
Fig. 8: Air Filter Box
Direct Vent
If outside air is drawn through the intake pipe directly
to the unit for combustion:
1. Install combustion air direct vent in accordance
with Fig. 27 (horizontal) or Fig. 28 (vertical) of this
manual (pages 28 and 29, respectively).
2. Provide adequate ventilation of the space occupied by the heater(s) by an opening(s) for
ventilation air at the highest practical point communicating with the outdoors. The total
cross-sectional area shall be at least 1 in.2of free
area per 20,000 BTUH (111 mm
input rating of all equipment in the room when the
opening is communicating directly with the outdoors or through vertical duct(s). The total
cross-sectional area shall be at least 1 in.
area per 10,000 BTUH (222 mm
input rating of all equipment in the room when the
opening is communicating with the outdoors
through horizontal duct(s).
3. In cold climates, and to mitigate potential freezeup, Raypak highly recommends the installation of
a motorized sealed damper to prevent the circulation of cold air through the heater during the
non-operating hours.
2
per kW) of total
2
2
per kW) of total
of free
TruSeal™ Combustion Air
In addition to the 3 previous steps, combustion air may
be ducted directly to the heater by using PVC, CPVC
Conventional Combustion Air
Supply
U.S. Installations
All Air from Inside the Building
The confined space shall be provided with TWO permanent openings communicating directly with an
additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for a
room large in comparison (NFGC). The total input of all
gas utilization equipment installed in the combined
space shall be considered in making this determination. Each opening shall have a minimum free area of
1 in.2per 1,000 BTUH (2,225 mm2per kW) of the total
input rating of all gas utilization equipment in the confined space, but not less than 100 in.2(645 cm2). One
opening shall commence within 12 in. (305 mm) of the
top, and one opening shall commence within 12 in.
(305 mm) of the bottom of the enclosure. The minimum dimension of air openings shall be not less than
3 in. (76 mm) in any direction.
All Air from Outdoors
The confined space shall communicate with the outdoors in accordance with one of the methods below.
The minimum dimension of air openings shall not be
less than 3 in. (76 mm) in any direction. Where ducts
are used, they shall be of the same cross-sectional
area as the net free area of the openings to which they
connect.
1. Two permanent openings, one commencing
within 12 in. (305 mm) of the top, and one commencing within 12 in. (305 mm) of the bottom of
11
the enclosure, shall be provided. The openings
shall communicate directly, or by ducts, with the
utdoors or spaces (crawl or attic) that freely com-
o
municate with the outdoors.
a. Where directly communicating with the out-
oors or where communicating to the
d
outdoors through vertical ducts, each open-
ing shall have a minimum free area of 1 in.
per 4,000 BTUH (550 mm2per kW) of total
input rating of all equipment in the enclosure.
b. Where communicating with the outdoors
through horizontal ducts, each opening shall
have a minimum free area of 1 in.2per 2,000
BTUH (1,100 mm2per kW) of total input rating of all equipment in the enclosure.
2. One permanent opening, commencing within 12
in. (305 mm) of the top of the enclosure, shall be
permitted where the equipment has clearances of
at least 1 in. (25 mm) from the sides and back and
6 in. (152 mm) from the front of the appliance. The
opening shall directly communicate with the outdoors or shall communicate through a vertical or
horizontal duct to the outdoors or spaces that
freely communicate with the outdoors, and shall
have a minimum free area of:
a. 1 in.2per 3,000 BTUH (740 mm2per kW) of
the total input rating of all equipment located in
the enclosure, and
b. Not less than the sum of the areas of all vent
connectors in the confined space.
WARNING: Do not use the “one permanent
opening” method if the equipment room is under
negative pressure conditions.
Canadian Installations
CAUTION: All combustion air must be drawn from
outside of the building; the mechanical equipment
room must communicate directly with the outdoors.
2. For heaters using a barometric damper in the vent
system there shall be a permanent air supply
pening(s) having a cross section area of not less
o
than 1 in.
2
per 7,000 BTUH (320 mm2per kW) up
to and including 1 million BTUH, plus 1 in.2per
14,000 BTUH (160 mm2per kW) in excess of 1
illion BTUH. This opening(s) shall be either
m
located at or ducted to a point not more than 18 in.
2
(450 mm) nor less than 6 in. (152 mm) above the
floor level. The duct can also “goose neck” through
the roof. The duct is preferred to be straight down
and terminated 18 in. (450 mm) from the floor, but
not near piping. This air supply opening requirement shall be in addition to the air opening for
ventilation air required in 1. (above).
WARNING: Care must be taken to ensure that the
equipment room is not under negative pressure
conditions.
3. For heaters not using a barometric damper in the
vent system, and when air supply is provided by
natural air flow from outdoors for a power burner
and there is no draft regulator, drafthood or similar
flue gas dilution device installed in the same
space, in addition to the opening for ventilation air
required in 1., there shall be a permanent air supply opening(s) having a total cross-sectional area
2
of not less than 1 in.
for each 30,000 BTUH (74
mm2per kW) of total rated input of the burner(s),
and the location of the opening(s) shall not interfere with the intended purpose of the opening(s)
for ventilation air referred to in 1. This opening(s)
can be ducted to a point not more than 18 in. (450
mm) nor less than 6 in. (152 mm) above the floor
level. The duct can also “goose neck” through the
roof. The duct is preferred to be straight down 18
in. (450 mm) from the floor, but not near piping.
4. Refer to the B149 Installation Code for additional
information.
Water Piping
1. Ventilation of the space occupied by the heater
shall be provided by an opening(s) for ventilation
air at the highest practical point communicating
with the outdoors. The total cross-sectional area of
such an opening(s) shall be at least 10% of the
area required in 2. and 3. (below), but in no case
shall the cross-sectional area be less than 10 in.
(65 cm2).
General
The heater should be located so that any water leaks
will not cause damage to the adjacent area or structures.
2
NOTE: In lieu of installing the System Temp Sensor
in the system return loop, an alternate system using
a buffer tank (see Fig. 31) can be used for better system temperature control.
12
CAUTION: This heater requires forced water
circulation when the burner is operating. See Table F
and Table G for minimum and maximum flow rates
and water pump selection. The pump must be
interlocked with the heater to prevent heater
peration without water circulation.
o
feed valve. Test at standard operating pressure for
at least 24 hours.
2. Make sure constant gauge pressure has been
maintained throughout test.
. Check for leaks. Repair if found.
3
NOTE: Minimum pipe size for in/out connections is
2 in. NPT for 504 and 754 models and 2-1⁄2 in NPT for
1104–2004 models. Verify proper flow rates and ∆T
as instructed in this manual.
Relief Valve Piping
WARNING: Pressure relief valve discharge piping
must be piped near the floor and close to a drain to
eliminate the potential of severe burns. Do not pipe
to any area where freezing could occur. Refer to
local codes.
Temperature & Pressure Gauge
The temperature and pressure gauge is shipped loose
for field installation and must be installed within 12
inches of the boiler outlet (if possible) in an easily
readable location. Installation must comply with ASME
Section IV as well as all applicable national, state and
local codes.
Hydrostatic Test
Unlike many types of heaters, this heater does not require hydrostatic testing prior to being placed in
operation. The heat exchanger has already been factory-tested and is rated for 160 psi operating pressure.
However, Raypak does recommend hydrostatic testing of the piping connections to the heater and the rest
of the system prior to operation. This is particularly
true for hydronic systems using expensive glycolbased anti-freeze. Raypak recommends conducting
the hydrostatic test before connecting gas piping or
electrical supply.
Leaks must be repaired at once to prevent damage to
the heater. NEVER use petroleum-based stop-leak
compounds.
To perform hydrostatic test:
1. Connect fill water supply. With bleed valve open,
fill heater with water. When water flows from bleed
valve, shut off water. Close bleed valve. Carefully
fill the rest of the system, making sure to eliminate
any entrapped air by using high-point vents. Close
Cold Water Operation
CAUTION: Damage due to internal condensation
may occur if the heater inlet water temperature does
not exceed 120°F (49°C) within 7 minutes of startup.
This heater is equipped with a proprietary condensate
evaporation system which will evaporate any condensate that may begin to accumulate inside the primary
heat exchanger with water temperatures as low as
120°F (49°C).
Heaters operated with an inlet temperature of less
than 120°F (49°C) MUST have a manual bypass (see
Fig. 16) or an approved low-temperature operation
system (Figs. 9 and 10) to prevent problems with condensation. This piping is similar to a
primary/secondary boiler installation, with a bypass
acting as the secondary boiler piping. Raypak strongly recommends that thermometer(s) be placed into the
heater piping next to the in/out header to facilitate temperature adjustment. Inlet water temperatures below
120°F (49°C) can excessively cool the products of
combustion, resulting in collection of condensate in the
heat exchanger area beyond the capacity of the condensate evaporation system.
Failure to reach or exceed 120°F (49°C) within 7 minutes may damage or cause failure of the heat
exchanger, combustion chamber, or other parts within
the combustion chamber. It can cause operational
problems, bad combustion, sooting, flue gas leakage
and reduced service life of the appliance and the vent
system. A bypass allows part of the heater discharge
water to be mixed with the cooler water returning to the
heater inlet to increase the heater inlet temperature
above 120°F (49°C). This precautionary measure
should prevent the products of combustion from condensing beyond the ability of the condensate
management system employed in this heater in most
installations. Warranty claims will be denied for
damage or failures caused by condensation.
Cold water operation issues are applicable to both
cold water start and cold water run applications. Cold
water operation for 7 minutes or less on initial daily
start-up is acceptable. Where cold water starts will last
13
longer than 7 minutes or where cold water operation is
*
*
continuous, provisions must be made to mix higher
emperature outlet water with the colder inlet water
t
and thereby raise the inlet temperature to at least
120°F (49°C) within the 7-minute time limit.
Cold Water Starts
Cold water starts, where the inlet water temperature
remains below 120°F (49°C) for more than 7 minutes,
have cold water start protection. Known pro-
must
tection methods consist of mixing heated outlet water
with the inlet water using a bypass to raise the inlet to
120°F (49°C) or higher. Once the system is heated up
and has return water temperatures of 120°F (49°C) or
higher, the mixing of outlet water with inlet water is no
longer needed and the bypass can be shut off. If the
bypass is not shut off as the system heats up, the outlet temperature may continue to climb and trip the high
limit, thereby shutting down the heater. Thus an automatic valve system, such as a three-way proportional
valve or a modulating two-way valve to control the
bypass, should be utilized.
and manually adjusted to achieve an inlet temperature
of 120°F (49°C) or higher as adjusted at the minimum
emperature in this narrow temperature range (i.e.
t
Range 75°F to 85°F – adjust bypass with temperature
at 75°F (24°C)) so that when temperature is 85°F
(29°C), minimum inlet temperature would be 130°F
54°C). An injector pump arrangement may also be uti-
(
lized to keep the heater loop at or above 120°F (49°C).
An injector pump approach has the added value of
being able to adjust to changes in the system water
coming back to the heater take-off.
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 9: Cold Water Start
Cold Water Run
Cold water run differs from cold water start in that the
system water entering the heater remains below
120°F (49°C) continuously. Typically, this is the case in
swimming pool heating. If the system water is kept in
a narrow temperature range of no more than 10°F
(5°C), a permanent manual bypass can be employed
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 10: Cold Water Run
Hydronic Heating
Pump Selection
In order to ensure proper performance of your heater
system, you must install a correctly-sized pump. Raypak requires designing for a ∆T within the range of
10°F to 40°F (5°C to 20°C). See Table F for acceptable flow rates for each model (∆T is the temperature
difference between the inlet and outlet water when the
heater is firing at full rate).
Feedwater Regulator
Raypak recommends that a feedwater regulator be installed and set at 12 psi minimum pressure at the
highest point of the system. Install a check valve or
back flow device upstream of the regulator, with a
manual shut-off valve as required by local codes.
14
T
HERMOSTAT OR
S
YSTEM SENSOR
THERMOSTATOR
SYSTEM SENSOR
Model
N
Input Output 20° ∆T 30° ∆T 40° ∆T Min. Flow Max. Flow
o.
MBTUH gpm ∆P gpm ∆P gpm ∆P gpm ∆P ∆T gpm ∆P ∆T
504 500 420 42 2.7 28 1.4 25 1.1 34 100 11.3 8
754 750 630 63 6.0 42 2.9 32 1.7 32 1.7 40 100 13.8 13
1104 1100 924 92 13.3 62 6.7 46 4.1 46 4.1 40 113 18.6 16
1504 1500 1260 84 13.3 63 8.0 63 8.0 40 113 22.2 22
2004 1999 1679 112 26.9 84 16.0 84 16.0 40 113 27.2 30
Note: Basis for minimum flow is ∆T. Basis for maximum flow is gpm.
Table F: Heater Rates of Flow and Pressure Drops
Piping
All high points should be vented. A heater installed
above radiation level must be provided with a low water cut-off device (sales order option F-10). This
heater, when used in connection with a refrigeration
system, must be installed so that the chilled medium is
piped in parallel with the heater with appropriate
valves to pre-vent the chilled medium from entering
the heater.
The piping system of a hot water heater connected to
heating coils located in air handling units where they
may be exposed to circulating refrigerated air, must be
equipped with flow control valves or other automatic
means to prevent gravity circulation of the heater
water during the cooling cycle. It is highly recommended that the piping be insulated.
Air-Separation/Expansion Tank
All heaters should be equipped with a properly sized
expansion tank and air separator fitting as shown in
Fig. 11.
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 12: Single Heater - Low-Temperature (Heat Pump)
Application with Primary/Secondary Piping
Fig. 11: Air-Separation/Expansion Tank
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 13: Dual Heaters (Reverse/Return)
with Primary/Secondary Piping
15
SYSTEM
SUPPLY
S
YSTEM
RETURN
Three-Way Valves
Three-way valves intended to regulate system water
temperatures by reducing flow in the boiler should not
be used. Raypak heaters are high-recovery, low-mass
eaters which are not subject to thermal shock. See
h
Fig. 16 and instructions on page 17 for adjusting the
manual bypass.
Domestic Hot Water
NOTE: If local codes require a vacuum relief valve,
acquire one locally and install per valve
manufacturer’s instructions.
Potable Water and Space Heating
CAUTION: When this heater is used for both
potable water and space heating, observe the
following to ensure proper operation.
When designing the water piping system for domestic
hot water applications, water hardness should be considered. Table G indicates the suggested flow rates for
soft, medium and hard water. Water hardness is expressed in grains per gallon.
Fig. 14: Single Domestic Hot Water Heater and Storage
Tank
1. All piping materials and components connected to
the water heater for the space heating application
shall be suitable for use with potable water.
2. Toxic chemicals, such as used for boiler treatment,
shall not be introduced into the potable water used
for space heating.
3. If the heater will be used to supply potable water,
it shall not be connected to any heating system or
components previously used with a non-potable
water heating appliance.
4. When the system requires water for space heating
at temperatures higher than 140°F (60°C), a
means such as a mixing valve shall be installed to
temper the water in order to reduce scald hazard
potential.
Pool Heating
When a boiler or water heater is used in a pool heating application, ensure that all the following installation
requirements are met.
Model
No.
504 500 420 17 50 3.6 2 5.9 13 65 5.5 2 9.3 9 95 10.4 2 18.1
754 750 630 25 50 4.0 2 6.3 20 65 6.4 2 10.2 13 100 13.8 2 22.2
1104 1045 888 30 60 6.4 2-1/2 7.6 20 92 13.2 2-1/2 15.9 16 113 18.7 2-1/2 22.6
1504 1425 1211 30 82 12.7 2-1/2 14.9 22 113 22.3 2-1/2 26.3 22 113 22.3 2-1/2 26.3
2004 1900 1615 30 110 26.1 2-1/2 29.8 29 113 27.4 2-1/2 31.3 29 113 27.4 2-1/2 31.3
∆T = Temperature rise, °F
∆P = Pressure drop through heat exchanger, ft
SHL = System head loss, ft (based on heater and tank placed no more than 5 ft apart and equivalent length of 50 eq ft of tubing)
gpm = Gallons per minute, flow rate
MTS = Minimum tubing size
*Must utilize optional cupro-nickel tubes. If over 25 grains per gallon, a water softener/treatment system must be utilized.
Caution: For scale free operation with "Hard Water" (16-25 grains per gallon of total hardness), the operating control must NOT be set
higher than 130°F. For higher than 130°F operation, a water softener/treatment system must be utilized.
MBTUH Soft (0-4 grains per gallon) Medium (5-15 grains per gallon) Hard* (16-25 grains per gallon)
Input Output ∆T gpm ∆P MTS SHL ∆T gpm ∆P MTS SHL ∆T gpm ∆P MTS SHL
Table G: Domestic Water Heater Flow Rate Requirements
16
The MVB must be equipped with a field-supplied ex-
*
POOL
THERMOSTAT
FROM
FILTER
TO POOL
C
HEMICAL
FEED
ternal pump and bypass arrangement. This
arrangement blends outlet water with the inlet water to
ncrease the inlet water temperature to a minimum of
i
105°F (40°C) for Pool Heater (P and WHP) versions
nd 120°F (49°C) for Hydronic Heating (H7) or
a
Domestic Hot Water (WH1) versions, thereby reducing
the likelihood of condensation forming on the heat
exchanger. The pump also serves to circulate water
through the heater from the main system piping.
CAUTION: Power to the heater should be
interlocked with the main system pump to make sure
the heater does not fire without the main system
pump in operation. Improper flow control can
damage the heater. Uncontrolled flow (too high) or
restricted flow (too low) can seriously damage the
heater. Follow these instructions to make sure your
heater is properly installed.
To complete the installation of the pool heater, the pool
thermostat must be installed in the main return water
line, upstream of the heater. This will ensure that the
heater will be energized at the right time.
1. Turn on pump.
2. Turn on heater and wait until heater goes to full
ire.
f
. With the heater operating at 100% firing rate, set
3
Valve A (the bypass) to
1
⁄2 open position, and Valve
B to fully open position. See Fig. 16.
4. Adjust Valve A until the inlet water temperature is
105°F (40°C) or 120°F (49°C) depending upon
heater type.
NOTE: Opening the valve will increase the
temperature and closing the valve will decrease the
temperature.
5. If this process does not raise the inlet water tem-
perature to 105°F (40°C) for Pool Heater (P and
WHP) versions and 120°F (49°C) for Hydronic
Heating (H7) or Domestic Hot Water (WH1) versions and Valve A is fully open, then slowly throttle
Valve B closed to increase the inlet water temperature to the required temperature.
*Maximum 4 times the pipe diameter or 12”, whichever is less.
Fig. 15: Single Pool Heater Application
Adjustment of the manual bypass valve is critical to
proper operation of the heater. The manual bypass
valve should be adjusted to achieve a minimum inlet
water temperature of 105°F (40°C) for Pool Heater (P
and WHP) versions and 120°F (49°C) for Hydronic
Heating (H7) or Domestic Hot Water (WH1) versions
and a system supply water temperature below 140°F
(60°C). When starting with a cold pool, make initial
adjustments. Make final adjustments when pool water
approaches desired temperature.
The use of a bypass is required for proper operation in
a pool heating application. Use the following instructions to set the manual bypass:
Fig. 16: “H” Bypass Setting
17
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